Variable geometry seasoning tumbler

ABSTRACT

The variable geometry seasoning tumbler is an adjustable tumbling device that allows for the uniform application of seasoning of snack food product such as potato chips, tortilla chips, corn chips, and the like. With the adjustable tumbling device, uniform application of seasoning can be achieved while minimizing snack food product breakage. The tumbler has adjustable upper and lower rolls that support a belt that receives and processes the snack food product. The belt has a catenary region wherein snack product is processed in a tumbling bed. By adjusting one or both rolls, the dimensions of the tumbling bed and the inclination of the belt can be easily modified. Thereby, the tumbling parameters can be optimized for each type of snack product being seasoned.

BACKGROUND OF THE INVENTION

[0001] 1. Technical Field

[0002] The present invention relates to an apparatus for applyingseasoning to snack food products such as potato chips, tortilla chips,corn chips, and the like. More particularly, the invention relates to anapparatus for applying seasoning uniformly by having an adjustableconfiguration that minimizes snack food product breakage duringapplication.

[0003] 2. Description of Related Art

[0004] Snack food products, particularly seasoned snacks, are popularsnack choices with consumers. For example, potato chips, tortilla chips,corn chips, and the like are seasoned prior packaging. To season, snackfood products are typically seasoned by sprinkling one or moreseasonings onto the surface of the snack food products while beingtumbled in a drum type tumbler. The seasonings for snacks include salt,barbecue flavoring, sour cream and onion flavor, vinegar flavor, cheese,and others.

[0005] Seasoning is spread onto the snacks by sprinkling on the surfaceof the products while being tumbled after they have been cooked. Theapplication and distribution of the seasoning onto the snacks is afactor in product quality. If the seasoning is not distributed evenlyonto the snacks, some snacks receive excessive amounts of the desiredquantity of seasoning while others receive less than desired amounts ofseasoning. Achieving the optimum compromise between uniform seasoningcoverage of the snack product along with minimum product breakagerequires selection of a tumbler drum with a particular design. Factorsinvolved in the proper selection include length, diameter, liftingflight design, tumbling RPM, and inclination angle. This depends on thesize, shape, bulk density, and production rate of the particular snackproduct being seasoned. Often, a tumbler drum must be used that is notideal because the drum seasons a variety of different products. Thisresults in a higher than necessary product breakage and sub-optimalseasoning coverage. Basically, the overall quality of the snacks will bepoor if the seasoning is not applied evenly or if a significant amountof snack product is broken. In addition to the aesthetic aspects ofseasoning distribution, economics suffer if the seasoning is appliedinefficiently or if snack product is broken.

[0006] In FIG. 1, a prior art seasoning applicator 10 is shown forseasoning snack food products 12. Unseasoned snack food products 12enters cylindrical tumbling drum 14 at one end through a funnel 18. Theend of the drum 14 through which the snack food products 12 areintroduced is elevated with respect to a discharge end 20. Thereby,snack food products 12 are moved by gravity toward discharge end 20. Asdrum 14 is axially rotated, baffles 16, which extend longitudinallyalong the interior surface of drum 14, lift food products 12 to aid inapplying the seasoning. A seasoning dispenser 22 has a tube portion 24that extends into drum 14. Within tube 24 is an auger 26 that is incommunication with seasoning hopper 30. As auger 26 is spun, seasoningfrom hopper 30 is carried through tube 24 and exits through apertures 32which are disposed on a portion of tube 24 that extends into drum 14. Asseasoning is supplied into drum 14, a seasoning curtain 34 is formedthrough which snack food products 12 pass through.

[0007] As shown in the prior art device of FIG. 1, conventionalseasoning devices utilize a tumbling drum to assist in apply seasoningonto snack food products. To achieve a uniform amount of seasoning oversnack product, the snack product must be tumbled in a tumbler with theproper characteristics, as described above. As it is more economical touse a single production line to make a variety of snack products, notall snack products are seasoned as uniformly as would otherwise bedesired. This is because with a variety of snack products havingdifferent sizes, shapes, and other characteristics are made with asingle production line, one tumbler must be selected that will bestseason all the different products. The result of this seasoning is oftensub-optimal coverage and product breakage.

[0008] Consequently, a need exists for a tumbling bed device that willassist in providing uniform seasoning coverage onto snack products whileminimizing product breakage. An applicator that can be modified toaccommodate the different products to be seasoned with a singleproduction line is desired. Thereby, snack products with uniformseasoning coverage can be produced while avoiding product breakage.

SUMMARY OF THE INVENTION

[0009] An exemplary embodiment of the invention is for a seasoningtumbler for applying seasoning onto snack food products such as potatochips, tortilla chips, corn chips, and the like. The seasoning tumblerhas an adjustable geometry in that a belt suspended between an upper andlower rolls that are each adjustable forms the tumbling bed. The beltextends transversely across a predetermined width wherein a slackportion, catenary portion, is formed in the belt. To support the rolls,support arms are provided at least at one for holding the rollscantilevered or, alternatively, support arms are provided at each sideof the rolls.

[0010] Snack food products fed onto the belt are tumbled in the catenaryportion which is formed on a top portion of the belt. To form thecatenary portion, the upper roll is suspended higher and backward fromthe lower roll. The belt is rotated by motion of the lower roll therebycreating the slack region. By having the entry point of the snack foodproduct onto the belt higher than its departure point, the snack foodproduct will travel along the belt in a downward manner. As snack foodproduct is lifted up along with the belt, the product reaches a pointwhere it is overcome by gravity and falls back toward the lower roll.The snack food product is then captured by the moving belt to repeatthis tumbling pattern. To aid the lifting of the product by the belt,flights or cleats can be optionally provide transversely andintermittently across the belt.

[0011] Advantageously, the geometry of the tumbling region is adjustableto optimize the application of the seasoning depending on the type ofproduct being seasoned. For example, the inclination of the belt isadjusted by adjusting the slope with movement of both rolls. Thereby,the tumbling time can be increased or decreased as needed. To adjust thecurvature of the catenary portion, the top roll can be moved eithertoward or away from the bottom roll. Thereby, the tumbling bed can bemade deeper or shallower. With the adjustability of the tumbling bed,multiple types of snack food can be seasoned uniformly with oneproduction line while minimizing product breakage.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The novel features believed characteristic of the invention areset forth in the appended claims. The invention itself, however, as wellas a preferred mode of use, further objectives and advantages thereof,will be best understood by reference to the following detaileddescription of illustrative embodiments when read in conjunction withthe accompanying drawings, wherein:

[0013]FIG. 1 is a cross-sectional side view of a rotating tumbling drumof the prior art applying a curtain of seasoning;

[0014]FIG. 2 is a top perspective view of a variable geometry seasoningtumbler of the invention;

[0015]FIG. 3 is a cross-sectional view of the variable geometryseasoning tumbler in FIG. 2 along showing the motion of the tumbling bedof snack food product being seasoned;

[0016]FIG. 4 is a top perspective view of the variable geometryseasoning tumbler in FIG. 2 showing snack food product being processed;

[0017]FIG. 5 is a cross-sectional view of the variable geometryseasoning tumbler in FIG. 2 showing curvature changes of the catenaryportion of the belt of the tumbler;

[0018]FIG. 6 is a cross-sectional view of the variable geometryseasoning tumbler in FIG. 2 showing movement of the upper support rollto effect a change in inclination in the tumbling bed; and

[0019]FIG. 7 is a front elevational view of the variable geometryseasoning tumbler in FIG. 2 showing movement of both support arms forboth rolls being adjusted to change the inclination of the entire belt.

DETAILED DESCRIPTION

[0020] Seasoned snack food products are produced with a tumbling beddevice in accordance with the invention are coated with seasoning. Inpractice, snack food products, such as potato chips, corn chips,tortilla chips, puffed-extruded cornmeal, or the like, are seasonedprior to being packaged for sale to consumers. With the tumbling beddevice made and used in accordance with the invention, seasoning appliedto snack food products with a seasoning dispenser are tumbled on thetumbling bed device that can be modified depending on the snackproducts' parameters.

[0021]FIG. 2 shows a preferred embodiment of the invention of variablegeometry seasoning tumbler 100. A support base 110 has ascending supportarm 120 for upper support roll 140 and ascending support arm 130 forlower support roll 142. The support rolls 140 and 142 can comprise drumrollers or large diameter sprockets. These rolls 140, 142 maybe retainedby shafts (not shown) that are held cantilevered as shown by support arm120, 130. Alternatively, rolls 140, 142 may be supported at the end,which is shown unattached in FIG. 2, by another set of support arms (notshown). These rolls 140, 142 support and retain belt 150 such that belt150 has a catenary portion 152 and a taut portion 154. The catenaryportion 152 is slack to allow snack food product to be tumbled withinthis region. On belt 150, flights 160 are provided along the surface ina transverse pattern for picking up snack food product being tumbled bytumbler 100. While belt 150 is shown with flights 160, alternativeprotrusions such as cleats may be used to aid in tumbling the snack foodproduct. Positioned beneath a portion of belt 150 is conveyor belt 170for receiving tumbled snack food product from belt 150.

[0022] The variable geometry seasoning tumbler 100 can be made fromconventional materials such as metal, plastic, and other materials.Particularly, rolls 140, 142 are generally comprised a durable materialthat can withstand the rotation and contact with belt 150. Likewise,belt 150 is generally comprised of a durable material capable ofwithstanding rotation and contact by rolls 140, 142 and contact withsnack food product that can have an elevated temperature above ambient.Belt 150 is rotated by rolls 140, 142 and is rotated in the directiontowards upper roll 140. Rotation is provided through the rotation oflower roll 142 to create the slack portion of catenary portion 152.Lower roll 142 can be rotated by a drive mechanism supplied throughascending support arm 130. By adjusting the speed of rolls 140, 142, thetumbling action, product residence time in the product tumbling bed(region of tumbling) of belt 150, and the product tumbling bed depth.

[0023] The effect of this rotation of belt 150 is shown in FIGS. 3 and4. Tumbling of snack food product 190 occurs generally in the catenaryportion 152. Seasoning 182 is supplied from a seasoning applicator 180that is positioned above belt 150 so that seasoning 182 will fall ontosnack food product 190 as it tumbles in catenary portion 152. Withtortilla chip seasoning, oil is applied to the surface of the chips topromote seasoning adhesion to the surface of the chips. Therefore, oilapplication equipment (not shown) is generally located toward theentrance of seasoning tumblers. With the instant invention, the oilapplication equipment would be located about where tortilla chips wouldbe introduced onto belt 150. Seasoning 182 is applied a shortlythereafter at a location further down belt 150. This minimizescontamination of the seasoning application equipment with oil.

[0024] The length of belt 150 wherein snack food product 190 is tumbledis optimally minimized to a length that includes the zones ofapplication of oil, if utilized, and seasoning, and the space betweenthe zones. In instances where no oil is applied, then the length wouldbe minimized to optimally be no longer than about the zone ofapplication for seasoning. Minimizing the time that snack food product190 is tumbled generally reduces the amount of snack food productbreakage.

[0025] The tumbling motion is exemplified in FIG. 3 wherein snack foodproduct 190 is tumbled in a product bed 162 with an elliptical path.This is similar to tumbling path that would occur in a conventionaltumbling drum. Snack food product 190 is supplied from snack foodproduct supply 200 onto belt 150. Depending on the amount of tumblingtime desired, the depositing position of snack food product onto belt150 can be altered by adjusting the position of supply 200. Thedepositing position is shown with arrow 202 and arrow 204 (shown inphantom to show an alternative position on belt 150). In addition to thedepositing position, tumbling time can be varied by adjusting therotational speed of belt 150, changing the inclination of the belt 150,or by some combination thereof. In a preferred embodiment however,having the ability to introduce the product to the tumbling area of belt150 farther along its length is desirable to adjust tumbling timeindependent of other factors to affect seasoning coverage.

[0026] Once deposited onto belt 150 at product entrance 156, snack foodproducts 190 are captured by flights 160 that protrude upward from belt150. The snack food product then travels upward towards roll 140 untilsnack food product 190 falls free from flights 160 due to the increasingslope of belt 150 as it travels upward toward roll 140. Snack foodproduct 190 will then fall back down toward roll 142 and will be pickedup again by more flights 160 rotating further down on belt 150 towardsthe product exit 158 on belt 150. This process repeats until snack foodproduct 190 reaches the exit on belt 150. The result of this process isthat the bed of tumbling snack food product is cradled and tumbled inthe catenary portion 152. After exiting belt 150, seasoned snack foodproduct 190 is then deposited onto belt 170 for transport to productpackaging or additional processing.

[0027]FIGS. 5 and 6 show different positions of rolls 140, 142 tocontrol the radius of curvature of the belt catenary and lateralinclination of the tumbling surface of belt 150. The radius of thetumbling surface is increased from R₁ to R₂ as shown in FIG. 5 by movingroll 140 backward away from roll 142. This results in moving belt 150from position P₁ to position P₂ (shown in phantom). The tumbling regionin catenary portion 152 can be adjusted to allow for narrow, deepproduct bed 162 with close roll spacing between rolls 140 and 142 or toallow for wide, shallow product bed 162 with wide roll spacing betweenrolls 140 and 142. With FIG. 6, by moving the roll 140 forward andupward relative to roll 142 will increase the inclination of thetumbling bed 162. This results in moving belt 150 from position P1 toposition P2 with snack food product being tumbled more rapidly.Selection of the positioning of rolls 140, 142 is dependent on theproduct being seasoned and the desired seasoning effect. By altering thehorizontal and vertical separation between rolls 140, 142, the tumblingaction and product bed depth can be controlled.

[0028] To change the inclination of the entire belt 150, both rolls 140,142 can be adjusted as shown in FIG. 7. When both rolls 140, 142 aremoved downward to increase the slope of tumbling bed 162, assembly 100moves from position P₁ to position P₄. As the slope is increased, therate of travel of snack food products 190 across belt 150 is increased.This is an additional parameter to control product seasoning.

[0029] With the above described invention, seasoning can be applied tosnack food product with uniform seasoning coverage with minimum productbreakage. The seasoning assembly achieves this with its flexible surfaceof variable curvature that is easily changeable to desirable parametersdepending upon the product being tumbled. Another advantage is that thetumbling device of the seasoning assembly is used to tumble product inan open environment as opposed to an internal surface of conventionaltumbling drum. This facilitates sanitation of the device and enables useof powder dispensers or coating applicators that are generally too largeto fit into the inside of a conventional tumbling drum.

[0030] While the invention has been particularly shown and describedwith reference to a preferred embodiment, it will be understood by thoseskilled in the art that various changes in form and detail may be madetherein without departing from the spirit and scope of the invention.

What is claimed is:
 1. A seasoning tumbler for use with seasoning snackfood product, comprising: an adjustable upper support roll; anadjustable lower support roll; and a belt suspended between the upperand the lower support rolls for receiving and processing the snack foodproduct wherein the belt has a catenary region for tumbling the snackfood product.
 2. The seasoning tumbler of claim 1 wherein the belt hasflights or cleats protruding from the belt surface for lifting the snackfood product upward towards the upper support roll.
 3. The seasoningtumbler of claim 1 wherein the belt is rotated through the rotation ofthe lower support roll causing the belt to rotate in the direction ofthe upper support roll.
 4. The seasoning tumbler of claim 3 wherein thespeed of rotation of the belt is adjustable.
 5. The seasoning tumbler ofclaim 1 wherein time that the snack food product is on the belt isadjustable.
 6. The seasoning tumbler of claim 1 wherein the snack foodproduct is fed onto the belt at a receiving point generally in thecatenary region.
 7. The seasoning tumbler of claim 6 wherein the snackfood product tumbles within the catenary region in a product bed.
 8. Theseasoning tumbler of claim 6 wherein the receiving point is located at aheight above a terminal end of the belt where processed snack foodproduct departs.
 9. The seasoning tumbler of claim 6 wherein theseasoning applicator is located above the catenary region.
 10. Theseasoning tumbler of claim 1 wherein a seasoning applicator is locatedabove the catenary portion of the belt.
 11. The seasoning tumbler ofclaim 1 wherein curvature of the catenary portion of the belt isadjustable.
 12. The seasoning tumbler of claim 11 wherein the curvatureadjustment is effected by the movement of the upper support roll. 13.The seasoning tumbler of claim 1 wherein slope of the belt from a snackproduct receiving point to a snack product departure point isadjustable.
 14. The seasoning tumbler of claim 13 wherein the slopeadjustment is effected by the joint movement of the upper and lowersupport rolls.
 15. The seasoning tumbler of claim 1 wherein the belt isadjustable to produce seasoned snack food product having uniformseasoning coverage.
 16. A seasoning tumbler for use with seasoning snackfood product, comprising: an adjustable upper support roll; anadjustable lower support roll; a belt having flights or cleats whereinthe belt is suspended between the upper and the lower support rolls forreceiving and processing the snack food product; and a catenary regionin the belt creating a tumbling product bed for the processing of thesnack food product.
 17. The seasoning tumbler of claim 16 wherein thebelt is rotated in the direction from the lower support roll toward theupper support roll, the speed of rotation being adjustable.
 18. Theseasoning tumbler of claim 16 wherein the belt has a receiving pointgenerally located in the catenary region and a terminal end whereprocessed snack food departs, the receiving point being located at aheight above the terminal end.
 19. The seasoning tumbler of claim 16wherein curvature of the catenary portion of the belt is adjustable withmovement of the upper support roll.
 20. The seasoning tumbler of claim16 wherein slope of the belt from a snack product receiving point to asnack product departure point is adjustable.
 21. The seasoning tumblerof claim 20 wherein the slope adjustment is effected by the jointmovement of the upper and lower support rolls.
 22. The seasoning tumblerof claim 16 wherein the upper support roll and the lower support rolleach connected to a support arm.